Article of footwear with dispensed components

ABSTRACT

A sole for an article of footwear includes a continuous dispensed component forming a first layer and a second layer. The first layer is disposed directly on top of the second layer. The continuous dispensed component forms a medial sidewall and a lateral sidewall. The first layer includes a starting point where the continuous dispensed component is first dispensed. The continuous dispensed component continuously transitions from the first layer to the second layer at the starting point.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.16/156,681, filed Oct. 10, 2018, which is incorporated herein byreference in its entirety.

BACKGROUND Field

Embodiments of the present invention relate generally to articles offootwear; and more specifically to articles of footwear with dispensedcomponents.

Background

Articles of footwear serve both functional purposes (e.g., protectingand cushioning the wearer's feet) and aesthetic purposes (e.g., forstyle). In addition to providing shoes that fulfill these purposes, shoemanufacturers seek to improve manufacturing efficiency. Thus, articlesof footwear that can be made efficiently while still achieving thewearer's functional and aesthetic needs are desirable.

BRIEF SUMMARY

Articles of footwear with dispensed components are disclosed. Thecomponents may be formed via an automated dispensing process that isdone robotically. In some embodiments, a sole for an article of footwearincludes a continuous dispensed component forming a first layer and asecond layer. In some embodiments, the first layer is disposed directlyon top of the second layer. In some embodiments, the continuousdispensed component forms a medial sidewall and a lateral sidewall. Insome embodiments, the first layer includes a starting point where thecontinuous dispensed component is first dispensed. In some embodiments,the continuous dispensed component continuously transitions from thefirst layer to the second layer at the starting point.

In some embodiments, the continuous dispensed component forms additionallayers. In some embodiments, the second layer is disposed directly ontop of the additional layers.

In some embodiments, the starting point is disposed at a midfoot of thesole.

In some embodiments, the continuous dispensed component forms aperimeter of the sole.

In some embodiments, the sole also includes an additional dispensedcomponent disposed within the perimeter of the sole. In someembodiments, the sole also includes a non-dispensed component disposedwithin the perimeter of the sole.

In some embodiments, an article of footwear includes an upper and a solecoupled to the upper. In some embodiments, the sole includes acontinuous dispensed component that forms a first layer and a secondlayer. In some embodiments, the first layer is aligned with the secondlayer. In some embodiments, the continuous dispensed component forms amedial sidewall and a lateral sidewall. In some embodiments, the firstlayer includes a starting point where the continuous dispensed componentis first dispensed. In some embodiments, the continuous dispensedcomponent continuously transitions from the first layer to the secondlayer at the starting point.

In some embodiments, the continuous dispensed component extends around aperimeter of the article of footwear. In some embodiments, the upperincludes a dispensed component. In some embodiments, the continuousdispensed component is directly coupled to the upper. In someembodiments, the sole includes a substrate disposed between the upperand the continuous dispensed component. In some embodiments, the upperincludes a circular knit material. In some embodiments, the continuousdispensed component forms additional layers.

In some embodiments, a method of making a sole for an article offootwear includes continuously dispensing a component to form a firstlayer of a medial sidewall and a lateral sidewall. In some embodiments,the first layer begins at a location and ends at the location. In someembodiments, the method also includes continuously dispensing thecomponent to form a step up region at the location and continuouslydispensing the component to form a second layer of the medial sidewalland the lateral sidewall. In some embodiments, the second layer isdisposed on top of the first layer and begins and ends at the location.In some embodiments, the second layer is continuous with the step upregion and the first layer.

In some embodiments, the method also includes continuously dispensingadditional layers of the medial sidewall and the lateral sidewall. Insome embodiments, the first layer is continuously dispensed onto anupper of the article of footwear. In some embodiments, the first layeris continuously dispensed onto a circular knit material disposed arounda last. In some embodiments, the first layer is continuously dispensedonto another component of the sole. In some embodiments, the location isdisposed at a medial edge of the sole.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a partof the specification, illustrate the present invention and, togetherwith the description, further serve to explain the principles of theinvention and to enable a person skilled in the pertinent art to makeand use the invention.

FIG. 1 shows a medial perspective view of an article of footwearaccording to some embodiments.

FIG. 2 shows a medial side view of a sole for an article of footwearaccording to some embodiments.

FIG. 3 shows a lateral side view of a sole for an article of footwearaccording to some embodiments.

FIG. 4 shows a bottom view of a sole for an article of footwearaccording to some embodiments.

FIG. 5 shows a side view of a continuous dispensed component forming afirst layer of a sole for an article of footwear according to someembodiments.

FIG. 6 shows a side view of a continuous dispensed component forming astep up region of a sole for an article of footwear according to someembodiments.

FIG. 7 shows a side view of a continuous dispensed component forming asecond layer of a sole for an article of footwear according to someembodiments.

FIG. 8 shows a top view of a sole for an article of footwear accordingto some embodiments.

FIG. 9 shows a lateral side view of an article of footwear according tosome embodiments.

DETAILED DESCRIPTION

The present invention will now be described in detail with reference toembodiments thereof as illustrated in the accompanying drawings, inwhich like reference numerals are used to indicate identical orfunctionally similar elements. References to “one embodiment”, “anembodiment”, “an example embodiment”, etc., indicate that the embodimentdescribed may include a particular feature, structure, orcharacteristic, but every embodiment may not necessarily include theparticular feature, structure, or characteristic. Moreover, such phrasesare not necessarily referring to the same embodiment. Further, when aparticular feature, structure, or characteristic is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art to affect such feature, structure,or characteristic in connection with other embodiments whether or notexplicitly described.

The term “invention” or “present invention” as used herein is anon-limiting term and is not intended to refer to any single embodimentof the particular invention but encompasses all possible embodiments asdescribed in the application.

The following examples are illustrative, but not limiting, of thepresent invention. Other suitable modifications and adaptations of thevariety of conditions and parameters normally encountered in the field,and which would be apparent to those skilled in the art, are within thespirit and scope of the invention.

Embodiments of the present invention provide articles of footwear havingone or more dispensed components created by an automated dispensingprocess. It is understood that while the term “dispensed” is generallyused herein to refer to certain materials, these materials may also be“extruded.” Thus, the term “dispensed component” includes componentsthat are dispensed and components that are extruded. These dispensedcomponents may be dispensed from a mechanical device. In someembodiments, the dispensed components are 3-D printed. In someembodiments, the dispensed components are not 3-D printed.

In some embodiments, an upper and/or a sole of the article of footwearmay have one or more dispensed components. In some embodiments, an upperand/or a sole, or portions thereof, can be formed from one or moredispensed components. In some embodiments, the dispensed component canbe a single, continuous piece of solid material. A dispensed footwearcomponent can have advantages over traditionally-formed components, suchas those made by casting, pouring, injection molding, screen-printing,or thermo-plastically forming. For example, a dispensed component can becustomized without having to machine a new, expensive mold. The use ofdispensed components can also allow for the use of shapes and geometriesthat are difficult to achieve using conventional upper or bottom moldingtechniques. Moreover, the data and knowledge to make a dispensedcomponent can be quickly deployed to any location that houses equipmentand material suitable for processing.

Various physical properties of the dispensed component can bemanipulated, adjusted, altered, and/or modified. For example, in someembodiments, the width, length, shape, wall thickness, color, density,elasticity, material, viscosity, hardness, number of layers, etc. of thedispensed component can vary along the dispensed component or between afirst and second dispensed component. As an example, a dispensedcomponent on an upper may be less viscous than a dispensed component ona sole, which can help the dispensed component on the upper lay flat. Asanother example, a dispensed upper component may be rigid in a firstportion, flexible in a second portion that is continuous with the firstportion, and rigid in a third portion that is continuous with the secondportion. The dispensed upper component may similarly vary in othercharacteristics, such as color or in the number of layers.

In some embodiments, the dispensed component can be made of rubber, foam(e.g., dispensed polyurethane foam), silicone, plastic includingthermoplastic (e.g., polyurethane (such as TPU), nylon, orpolypropylene), or any other suitable material. In some embodiments, thedispensed component can be made of a composite material. In someembodiments, the cross-section of the dispensed component can besubstantially circular, oval, rectangular, triangular, square, or anyother suitable shape or design (e.g., star-shaped). In some embodiments,the cross-section of the dispensed component can be relatively flat(i.e., low profile). Moreover, the cross-section of the dispensedcomponent may be adjusted dynamically and may vary throughout theautomated dispensing process. In some embodiments, the dispensedcomponent can be dispensed directly onto the article of footwear, suchas directly onto the sole (e.g., insole, midsole, and/or outsole) or theupper. For example, the dispensed component can be dispensed directlyonto a formed upper on a last (e.g., a flat knit upper, a circular knitupper, a formed three-dimensional knit, a sock, a fully-finishedtraditionally-lasted upper, etc.). The upper may be made of a textilefabric, leather, synthetic, or film product. In some embodiments, thedispensing or extruding is done automatically (i.e., robotically). Insome embodiments, a scanner may scan the upper and then roboticallydispense the dispensed component onto the upper based on the scan.

In some embodiments, the dispensed component may bond (e.g., by thermalfusion, chemical adhesion, or mechanical locking) to a portion of thearticle of footwear. In some embodiments, the dispensed component mayform a portion of the sole of the article of footwear. In someembodiments, one or more dispensed components may form the entire soleof the article of footwear. In some embodiments, a single, continuousdispensed component forms a medial sidewall and a lateral sidewall. Insome embodiments, the sidewalls each have multiple layers (all formedfrom the single, continuous dispensed component). In some embodiments,the layers are disposed directly on top of each other so that they arealigned with each other. In some embodiments, the continuous dispensedcomponent has a starting point (i.e., where it is first dispensed). Insome embodiments, each layer begins and ends at the starting point andthe continuous dispensed component continuously dispenses to form a stepup region from one layer to the next. Forming the sole with a dispensedcomponent may provide flexibility and speed in development andmanufacturing of the sole, while still meeting the functional andaesthetic purposes of the sole.

In some embodiments, the article of footwear may include or utilize anyof the extruded/dispensed components or other features disclosed in U.S.application Ser. No. 14/455,650, filed Aug. 8, 2014, U.S. applicationSer. No. 14/945,077, filed Nov. 18, 2015, U.S. application Ser. No.15/644,463, filed Jul. 7, 2017, and/or U.S. application Ser. No.15/831,851, filed Dec. 5, 2017, the disclosures of which areincorporated herein in their entireties by reference thereto.

In some embodiments, dispensed components may be utilized in an articleof footwear 10, as shown, for example, in FIG. 1. In some embodiments,article of footwear 10 comprises an upper 20 and a sole 30. In someembodiments, upper 20 and sole 30 are coupled together. In someembodiments, upper 20 comprises one or more dispensed components 22. Insome embodiments, sole 30 comprises one or more dispensed components 32.In some embodiments, article of footwear 10 comprises both upperdispensed component(s) 22 and sole dispensed component(s) 32 (see FIG.1). However, in some embodiments, article of footwear 10 may includeeither sole dispensed component(s) 32 or upper dispensed component(s)22, and not both.

In some embodiments, dispensed components 22, 32 may be dispensed onto asurface so as to provide a dispensed component that extends above thesurface at a certain width and height profile. In some embodiments, theheight, width, or geometry or physical appearance/characteristic of thedispensed components may be dynamically changed as the components aredispensed onto article of footwear 10, such as onto upper 20, sole 30,or another surface (e.g., another layer of a dispensed component). Insome embodiments, the geometry or physical appearance/characteristics ofthe dispensed components may be changed by dynamically changing theheight of the nozzle (relative to the dispensing surface or substrate)from which the material, used to form the component, is dispensed. Insome embodiments, the geometry or physical appearance/characteristics ofthe dispensed components may be changed by dynamically changing thespeed at which the nozzle is moving as the material is dispensed and thecomponent is formed. In some embodiments, the geometry or physicalappearance/characteristics of the dispensed components may be changed bydynamically changing the flow rate of the material that is dispensed.Other parameters may be changed to dynamically change the height, width,or other characteristic of the dispensed components. In someembodiments, the density or viscosity of the dispensed components may bechanged.

Upper 20 may be made of a variety of materials (e.g., a textile fabric,woven or knit goods, leather, synthetic, a film product, etc.). Forexample, upper 20 may be a circular knit material. In some embodiments,upper 20 may be made of a combination of these materials.

At least a portion of sole 30 may be made with dispensed component 32.Dispensed component 32 may provide a sole 30 that fulfills bothfunctional and aesthetic purposes and can be manufactured efficiently.In some embodiments, sole 30 is made entirely of one or more dispensedcomponents 32.

In some embodiments, dispensed component 32 forms a medial sidewall 36(see FIGS. 1-2). In some embodiments, dispensed component 32 forms alateral sidewall 38 (see FIG. 3). In some embodiments, dispensedcomponent 32 forms a perimeter 18 of sole 30. In some embodiments,perimeter 18 extends around the entire perimeter of article of footwear10. In some embodiments, perimeter 18 (including medial sidewall 36 andlateral sidewall 38) is formed by a single, continuous dispensedcomponent 32.

In some embodiments, continuous dispensed component 32 forms a pluralityof layers 40, 42, 44, 46 to form medial sidewall 36 and lateral sidewall38. In some embodiments, first layer 40 of continuous dispensedcomponent 32 is dispensed directly onto a bottom surface of the upper 20to form at least a portion of sole 30 (see FIGS. 1 and 5). In someembodiments, first layer 40 of continuous dispensed component 32 isdispensed onto a substrate 28 (see FIG. 9). In some embodiments,subsequent layers are dispensed directly onto the previous layer. Thus,in the completed sole 30, first layer 40 may be disposed directly on topof second layer 42, second layer 42 may be disposed directly on topthird layer 44, and third layer 44 may be disposed directly on top offourth layer 46. In some embodiments, each of layers 40, 42, 44, 46 arealigned with each other.

In some embodiments, first layer 40 comprises a starting point atlocation 50 where continuous dispensed component 32 is first dispensed.In some embodiments, location 50 is disposed at a medial edge of sole30. In some embodiments, location 50 is disposed at a lateral edge ofsole 30. In some embodiments, location 50 is disposed in a midfoot 14 ofsole 30, as shown, for example, in FIG. 2. In some embodiments, location50 is disposed in a heel 12 or a forefoot 16 of sole 30.

In some embodiments, first layer 40 extends from location 50 aroundperimeter 18 of sole 30 until it again reaches location 50. Thus, firstlayer 40 may begin and end at location 50. In some embodiments,continuous dispensed component 32 continues to be dispensed onto firstlayer 40, thus forming second layer 42. Second layer 42 may follow firstlayer 40 around perimeter 18 of sole 30 until it reaches location 50.For example, second layer 42 may be aligned with first layer 40. Thus,second layer 42 may begin and end at location 50. In some embodiments,second layer 42 is dispensed onto first layer 40 so that first layer 40is disposed directly on top of second layer 42.

Additional layers, such as third layer 44 and fourth layer 46, may beformed using the same dispensing process. This dispensing process formsa step up region 52 disposed at location 50. At step up region 52,continuous dispensed component 32 steps up from one layer to the next.Thus, multiple layers (for example, each of layers 40, 42, 44, 46) maybe formed from a single continuous dispensed component 32. The combinedlayers 40, 42, 44, 46 may form both medial sidewall 36 (as shown in FIG.2) and lateral sidewall 38 (as shown in FIG. 3). In some embodiments,the continuous dispensed component 32 forms a perimeter of sole 30. Insome embodiments, the continuous dispensed component 32 extends around aperimeter of article of footwear 10.

FIGS. 5-7 illustrate an example dispensing process to form sole 30 withcontinuous dispensed component 32. In some embodiments, continuousdispensed component 32 is dispensed directly onto upper 20 to form sole30. For example, in some embodiments, upper 20 is disposed on a last 26.In some embodiments, upper 20 may be a knit material, such as a circularknit material 24 (see FIGS. 5-7). Other types of materials may also beused for upper 20 with the dispensing process.

In some embodiments, as shown, for example, in FIGS. 5-7, the componentis dispensed from a nozzle 54. In some embodiments, the relativeposition of nozzle 54 and upper 20 is adjustable. In some embodiments,nozzle 54 is movable. In some embodiments, last 26 is movable. In someembodiments, both nozzle 54 and last 26 are movable. Nozzle 54 may bedisposed at location 50 when it begins dispensing. In some embodiments,nozzle 54, last 26, or both begins to move when nozzle 54 startsdispensing. As the relative position of nozzle 54 and upper 20 changes,nozzle 54 continuously dispenses first layer 40, as shown in FIG. 5. Anypattern may be used for first layer 40. In some embodiments, the patternof first layer 40 goes around the perimeter of upper 20 to formperimeter 18 of sole 30.

In some embodiments, nozzle 54 returns again to location 50, as shown,for example, in FIG. 6. As nozzle 54 passes over location 50, nozzle 54continues to dispense a continuous component, thus forming step upregion 52 where continuous dispensed component 32 steps up from firstlayer 40 to second layer 42. Thus, the transition from first layer 40 tosecond layer 42 may be a smooth transition without discontinuity. Insome embodiments, second layer 42 is continuous with step up region 52and first layer 40. In some embodiments, continuous dispensed component32 continuously transitions from first layer 40 to second layer 42 atthe starting point or location 50.

In some embodiments, nozzle 54 continues to dispense component 32 toform second layer 42, as shown, for example, in FIG. 7. As discussedabove, second layer 42 may be aligned with first layer 40. Thus, whenarticle of footwear 10 is in use, first layer 40 is disposed directly ontop of second layer 42. Additional layers (e.g., third layer 44 andfourth layer 46) may be formed by continuing this same dispensingprocess. Each transition between layers is located at step up region 52,which is at location 50.

A similar dispensing process may be used even when continuous dispensedcomponent 32 is not dispensed directly onto upper 20. For example, sole30 may include a substrate 28 (see FIG. 9) and continuous dispensedcomponent 32 may be dispensed onto substrate 28 in a similar manner asthe process described with respect to FIGS. 5-7. As shown in FIG. 9, insome embodiments, substrate 28 is disposed between upper 20 andcontinuous dispensed component 32.

This dispensing process forms an aesthetically pleasing sole. Other thanstep up region 52, each layer 40, 42, 44, 46 appears to be a distinctlayer separate from other layers, giving sole 30 a clean look, as shown,for example, in FIG. 3. Even at step up region 52, because each layersteps up together, sole 30 maintains a clean look, as shown, forexample, in FIG. 2.

In some embodiments, sole 30 comprises one or more additional components34 in addition to dispensed component 32, as shown, for example, inFIGS. 4 and 8. In some embodiments, additional components 34 may bedisposed within perimeter 18 (e.g., between medial sidewall 36 andlateral sidewall 38), as shown, for example, in FIG. 4. In someembodiments, additional component 34 is a non-dispensed component. Insome embodiments, as in FIG. 4, additional component 34 is a dispensedcomponent. In some embodiments, sole 30 includes an additional component34 that is formed with a dispensed component in a similar manner asdescribed above with respect to continuous dispensed component 32, butis dispensed within continuous dispensed component 32, as shown in FIGS.4 and 8. For example, sole 30 in FIGS. 4 and 8 includes additionalcomponent 34 that follows along an interior side of continuous dispensedcomponent 32, thus forming a smaller version of medial sidewall 36 andlateral sidewall 38 within perimeter 18. In some embodiments, additionalcomponent 34 may be dispensed with a different pattern than continuousdispensed component 32. For example, as shown in FIGS. 4 and 8, sole 30may include an additional component 34 disposed in forefoot 16. Althoughadditional component 34 may have a different pattern, the formation oflayers may be the same as continuous dispensed component 32. Additionalcomponents 34 may function to provide additional support for the wearer.

In some embodiments, sole 30 comprises an outsole 48. In someembodiments, outsole 48 comprises a non-dispensed component. In someembodiments outsole 48 comprises a dispensed component 32. In someembodiments, outsole 48 may be formed with the same continuous dispensedcomponent 32 that forms layers 40, 42, 44, 46. In some embodiments, evenwhere outsole 48 is the same continuous dispensed component 32 thatforms layers 40, 42, 44, 46, at least one characteristic of dispensedcomponent is different for outsole 48 than for the other layers 40, 42,44, 46. For example, outsole 48 may be a different color, viscosity,density, thickness, etc., or a combination of these characteristics. Insome embodiments, outsole 48 is disposed on continuous dispensedcomponent 32 and additional components 34 (see FIG. 4). In someembodiments, outsole 48 includes multiple, distinct pieces. For example,outsole 48 may include a first piece that is disposed on continuousdispensed component 32 and an additional component 34 and a second piecethat is disposed only on a different additional component 34. In someembodiments, outsole 48 includes only a single piece.

Various embodiments described herein provide an article of footwear thatprotects and cushions the wearer's foot, while also fulfilling aestheticpurposes. Moreover, manufacturing this article of footwear is efficient.Further variations of the embodiments described above may also beprovided.

The foregoing description of the specific embodiments will so fullyreveal the general nature of the invention that others can, by applyingknowledge within the skill of the art, readily modify and/or adapt forvarious applications such specific embodiments, without undueexperimentation, without departing from the general concept of thepresent invention. Therefore, such adaptations and modifications areintended to be within the meaning and range of equivalents of thedisclosed embodiments, based on the teaching and guidance presentedherein. It is to be understood that the phraseology or terminologyherein is for the purpose of description and not of limitation, suchthat the terminology or phraseology of the present specification is tobe interpreted by the skilled artisan in light of the teachings andguidance.

The breadth and scope of the present invention should not be limited byany of the above-described exemplary embodiments, but should be definedonly in accordance with the following claims and their equivalents.

What is claimed is:
 1. A method of making a sole for an article offootwear, the method comprising: continuously dispensing a component toform a first layer of a medial sidewall and a lateral sidewall, thefirst layer beginning at a location and ending at the location;continuously dispensing the component to form a step up region at thelocation; and continuously dispensing the component to form a secondlayer of the medial sidewall and the lateral sidewall, the second layerdisposed on top of the first layer and beginning and ending at thelocation, wherein the second layer is continuous with the step up regionand the first layer.
 2. The method of claim 1, further comprisingcontinuously dispensing additional layers of the medial sidewall and thelateral sidewall.
 3. The method of claim 1, wherein the first layer iscontinuously dispensed onto an upper of the article of footwear.
 4. Themethod of claim 1, wherein the first layer is continuously dispensedonto a circular knit material disposed around a last.
 5. The method ofclaim 1, wherein the first layer is continuously dispensed onto anothercomponent of the sole.
 6. The method of claim 1, wherein the location isdisposed at a medial edge of the sole.